Apparatuses and methods for making absorbent articles

ABSTRACT

The present disclosure relates to methods and apparatuses for assembling diapers, each including a chassis connected with front and back elastic belts. As discussed in more detail below, opposing end regions of the chassis are connected with regions of the elastic belts where the elasticity of the elastic belts has been removed or deactivated. An elastic laminate may be formed by continuously bonding elastic strands between a first continuous substrate layer and a second continuous substrate layer such that the elastic strands are bonded to both the first substrate layer and the second substrate layer in heavy-bond regions. And the elastic strands are bonded to the first substrate layer and/or the second substrate layer with in light-bond regions. The elastic strands are then intermittently deactivated by cutting the strands into one or more discrete pieces in the light-bond regions. The discrete pieces retract and remain in the light-bond regions.

FIELD OF THE INVENTION

The present disclosure relates to methods for manufacturing absorbentarticles, and more particularly, to apparatuses and methods for makingelastic belts for diapers.

BACKGROUND OF THE INVENTION

Along an assembly line, various types of articles, such as for example,diapers and other absorbent articles, may be assembled by addingcomponents to and/or otherwise modifying an advancing, continuous web ofmaterial. For example, in some processes, advancing webs of material arecombined with other advancing webs of material. In other examples,individual components created from advancing webs of material arecombined with advancing webs of material, which in turn, are thencombined with other advancing webs of material. In some cases,individual components created from advancing web or webs are combinedwith other individual components created from other advancing web orwebs. Webs of material and component parts used to manufacture diapersmay include: backsheets, topsheets, leg cuffs, waist bands, absorbentcore components, front and/or back ears, fastening components, andvarious types of elastic webs and components such as leg elastics,barrier leg cuff elastics, stretch side panels, and waist elastics. Oncethe desired component parts are assembled, the advancing web(s) andcomponent parts are subjected to a final knife cut to separate theweb(s) into discrete diapers or other absorbent articles.

Some diaper pant embodiments are configured with a chassis connectedwith front and back elastic belts, wherein opposing end regions of thefront and back belts are connected with each other at side seams. Insome instances, the elasticity of the front and back belts is removed inregions where the chassis connects with the belts. In someconfigurations, diapers may include graphics on the belts or in beltregions, and the absence of elasticity in such regions may allow forreduced distortion of graphics located in those regions. Thus, in someconverting configurations adapted to assemble such diaper pants,stretched elastic strands are glued between two continuous nonwoven websto form an elastic laminate. Regions of the elastic strands may then beintermittently deactivated along the length of the elastic laminate bycutting the elastic strands. Subsequent to deactivating the elasticstrands, the elastic laminate may be subjected to additional handlingand converting operations.

However, cutting the elastic strands may also damage other materials ofthe elastic laminate, for example the nonwoven webs, resulting in arelatively poor aesthetic appearance. In addition, the ends of the cutelastic stands may snap back in an uncontrolled fashion and consequentlymay end up in an undesired location within the laminate and may form awad of elastic which may negatively impact comfort, quality impressionand aesthetics. Further, deactivating the elastics in an elasticlaminate may weaken the laminate, making the laminate relatively morelikely to tear, and/or may otherwise result in control and handlingdifficulties associated with differential stretch characteristics withinthe laminate during subsequent processing. Consequently, it would bebeneficial to provide methods and apparatuses that are configured tominimize handling of the elastic laminates after intermittentlydeactivating the elastics therein; and/or assemble the elastic laminatein such a way to maximize the aesthetic appearance of the laminate whenplaced in an assembled product.

SUMMARY OF THE INVENTION

The present disclosure relates to methods and apparatuses for assemblingdiapers, each including a chassis connected with front and back elasticbelts. As discussed in more detail below, opposing end regions of thechassis are connected with regions of the elastic belts where theelasticity of the elastic belts has been removed or deactivated. Anelastic laminate may be formed by continuously bonding elastic strandsbetween a first continuous substrate layer and a second continuoussubstrate layer such that the elastic strands are bonded to both thefirst substrate layer and the second substrate layer in heavy-bondregions. And the elastic strands are bonded to the first substrate layerand/or the second substrate layer with in light-bond regions. Theelastic strands are then intermittently deactivated by cutting thestrands into one or more discrete pieces in the light-bond regions. Thediscrete pieces retract and remain in the light-bond regions.

In one form, a method may be adapted to assemble disposable diapers,each diaper comprising a chassis having a first end region and anopposing second end region separated from each other by a centralregion, and having a longitudinal axis and a lateral axis, the chassiscomprising: a topsheet, a backsheet, and an absorbent core disposedbetween the topsheet and the backsheet. The method includes the stepsof: advancing a first continuous substrate layer having a first surfaceand an opposing second surface in a machine direction, and defining awidth in a cross direction; advancing a second continuous substratelayer having a first surface and an opposing second surface in a machinedirection, and defining a width in a cross direction; applying a firstadhesive continuously along the machine direction to the first surfaceof the first continuous substrate layer; advancing elastic strands inthe machine direction in a stretched state; applying a second adhesiveintermittently along the machine direction to at least one of theelastic strands, the first surface of the first continuous substratelayer, and the first surface of the second continuous substrate layer;placing the elastic strands in the stretched state between the firstsurface of the first substrate layer and the first surface of the secondsubstrate layer to form an elastic laminate, the elastic laminateincluding first regions that include the first adhesive and not thesecond adhesive, and second regions including both the first adhesiveand the second adhesive, the second regions intermittently spaced alongthe machine direction; cutting the elastic laminate along the machinedirection to form a first continuous elastic laminate and a secondcontinuous elastic laminate, each of the first continuous elasticlaminate and the second continuous elastic laminate including firstregions and second regions; separating the first continuous elasticlaminate and the second elastic laminate in the cross direction;severing elastic strands into one or more discrete lengths in the firstregions of the first continuous elastic laminate and the second elasticlaminate, wherein ends of the severed elastic strands retract from thefirst regions to the second regions; and bonding the first end regionsof each chassis with first regions of first continuous elastic laminate,and bonding the second end regions of each chassis with first regions ofthe second continuous elastic laminate.

In another form, a method may be configured for assembling disposablediapers, each diaper comprising a chassis having a first end region andan opposing second end region separated from each other by a centralregion, and having a longitudinal axis and a lateral axis, the chassiscomprising: a topsheet, a backsheet, and an absorbent core disposedbetween the topsheet and the backsheet. The method includes the stepsof: advancing a first continuous substrate layer having a first surfaceand an opposing second surface in a machine direction, and defining awidth in a cross direction; advancing a second continuous substratelayer having a first surface and an opposing second surface in a machinedirection, and defining a width in a cross direction; applying a firstadhesive continuously along the machine direction to the first surfaceof the first continuous substrate layer; advancing elastic strands inthe machine direction in a stretched state; applying a second adhesiveintermittently along the machine direction to at least one of theelastic strands, the first surface of the first continuous substratelayer, and the first surface of the second continuous substrate layer;placing the elastic strands in the stretched state between the firstsurface of the first substrate layer and the first surface of the secondsubstrate layer to form an elastic laminate, the elastic laminateincluding first regions that include the first adhesive and not thesecond adhesive, and second regions including both the first adhesiveand the second adhesive, the second regions intermittently spaced alongthe machine direction; and severing elastic strands into one or morediscrete lengths in the first regions of the elastic laminate, whereinthe ends of the severed elastic strands retract from the first regionsto the second regions.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a diaper pant.

FIG. 2A is a partially cut away plan view of the diaper pant shown inFIG. 1.

FIG. 2B is a partially cut away plan view of a second embodiment of adiaper pant.

FIG. 3A is a cross-sectional view of the diaper pants of FIGS. 2A and 2Btaken along line 3A-3A.

FIG. 3B is a cross-sectional view of the diaper pants of FIGS. 2A and 2Btaken along line 3B-3B.

FIG. 4 is a schematic side view of a converting apparatus adapted tomanufacture pre-fastened, pant diapers.

FIG. 4A shows a first alternative converting embodiment for forming anelastic laminate.

FIG. 4A1 is a view of a continuous length of an elastic laminate fromFIG. 4A taken along line 4A1-4A1.

FIG. 4B shows a second alternative converting embodiment for forming anelastic laminate.

FIG. 4B1 is a view of a continuous length of an elastic laminate fromFIG. 4B taken along line 4B1-4B1.

FIG. 4B2 is a view of a continuous length of an elastic laminate fromFIG. 4B taken along line 4B2-4B2.

FIG. 5A is a view of a continuous length of an elastic laminate fromFIG. 4 taken along line 5A-5A.

FIG. 5B is a view of the elastic laminate from FIG. 4 after being slitinto first and second belt substrates separated from each other in thecross direction CD taken along line 5B-5B.

FIG. 5B1 is a cross-sectional view of the first belt substrate from FIG.5B taken along line B1-B1.

FIG. 5B2 is a cross-sectional view of the second belt substrate fromFIG. 5B taken along line B2-B2.

FIG. 5B3 shows a detailed view of a belt substrate with the outer layerbelt material cut-away to illustrate an adhesive application embodiment.

FIG. 5C is a view of continuous lengths of advancing first and secondbelt substrates material from FIG. 4 taken along line 5C-5C.

FIG. 5C1 is a view of the first and second belt substrates material fromFIG. 5C with the outer layer belt material cut-away to illustrate thedeactivated elastics in the light-bond regions.

FIG. 5C2 is a cross-sectional view of the first belt substrate from FIG.5C taken along line C2-C2 showing deactivated elastics in the light-bondregions.

FIG. 5C3 is a cross-sectional view of the second belt substrate fromFIG. 5C taken along line C3-C3 showing deactivated elastics in thelight-bond regions.

FIG. 5C4 shows a detailed view of a belt substrate from FIG. 5C with theouter layer belt material cut-away to illustrate the deactivatedelastics in the light-bond regions.

FIG. 5C2A is a cross-sectional view of the first belt substrate fromFIG. 5C taken along line C2-C2 showing elastics and inner belt materialcut in light-bond regions.

FIG. 5C3A is a cross-sectional view of the second belt substrate fromFIG. 5C taken along line C3-C3 showing elastics and inner belt materialcut in light-bond regions.

FIG. 5C2B is a cross-sectional view of the first belt substrate fromFIG. 5C taken along line C2-C2 showing elastics, inner belt material,and outer belt material cut in light-bond regions.

FIG. 5C3B is a cross-sectional view of the second belt substrate fromFIG. 5C taken along line C3-C3 showing elastics, inner belt material,and outer belt material cut in light-bond regions.

FIG. 5D is a view of a continuous length of chassis assemblies from FIG.4 taken along line D-D.

FIG. 5E1 is a view of a discrete chassis from FIG. 4 taken along line5E1-5E1.

FIG. 5E2 is a view of a discrete chassis from FIG. 4 taken along line5E2-5E2.

FIG. 5F is a view of multiple discrete chassis spaced from each otheralong the machine direction MD and connected with each other by thefront and back side panel material from FIG. 4 taken along line 5F-5F.

FIG. 5G is a view of folded multiple discrete chassis with the front andback side panel material in a facing relationship from FIG. 4 takenalong line 5G-5G.

FIG. 5H is a view of two discrete absorbent articles advancing themachine direction MD from FIG. 4 taken along line 5H-5H.

FIG. 6 is a perspective view of an embodiment of a cutting apparatus.

FIG. 7 is a front side view of the cutting apparatus of FIG. 6 as twoblades are rotated toward two substrates partially wrapped around ananvil roll.

FIG. 8A is a left side view of the cutting apparatus of FIG. 7 showingthe blade initiating contact with the substrate partially wrapped aroundthe anvil roll.

FIG. 8B shows the cutting apparatus of FIG. 8A as the blade flexes whilebeing rotated into contact with the substrate partially wrapped aroundthe anvil roll.

FIG. 8C shows the cutting apparatus of FIG. 8B after the blade isrotated away from the substrate partially wrapped around the anvil roll.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding thepresent disclosure:

“Absorbent article” is used herein to refer to consumer products whoseprimary function is to absorb and retain soils and wastes. “Diaper” isused herein to refer to an absorbent article generally worn by infantsand incontinent persons about the lower torso. The term “disposable” isused herein to describe absorbent articles which generally are notintended to be laundered or otherwise restored or reused as an absorbentarticle (e.g., they are intended to be discarded after a single use andmay also be configured to be recycled, composted or otherwise disposedof in an environmentally compatible manner).

An “elastic,” “elastomer” or “elastomeric” refers to materialsexhibiting elastic properties, which include any material that uponapplication of a force to its relaxed, initial length can stretch orelongate to an elongated length more than 10% greater than its initiallength and will substantially recover back to about its initial lengthupon release of the applied force.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

“Longitudinal” means a direction running substantially perpendicularfrom a waist edge to a longitudinally opposing waist edge of anabsorbent article when the article is in a flat out, uncontracted state,or from a waist edge to the bottom of the crotch, i.e. the fold line, ina bi-folded article. Directions within 45 degrees of the longitudinaldirection are considered to be “longitudinal.” “Lateral” refers to adirection running from a longitudinally extending side edge to alaterally opposing longitudinally extending side edge of an article andgenerally at a right angle to the longitudinal direction. Directionswithin 45 degrees of the lateral direction are considered to be“lateral.”

The term “substrate” is used herein to describe a material which isprimarily two-dimensional (i.e. in an XY plane) and whose thickness (ina Z direction) is relatively small (i.e. 1/10 or less) in comparison toits length (in an X direction) and width (in a Y direction).Non-limiting examples of substrates include a web, layer or layers orfibrous materials, nonwovens, films and foils such as polymeric films ormetallic foils. These materials may be used alone or may comprise two ormore layers laminated together. As such, a web is a substrate.

The term “nonwoven” refers herein to a material made from continuous(long) filaments (fibers) and/or discontinuous (short) filaments(fibers) by processes such as spunbonding, meltblowing, carding, and thelike. Nonwovens do not have a defined woven or knitted filament pattern.

The term “machine direction” (MD) is used herein to refer to thedirection of material flow through a process. In addition, relativeplacement and movement of material can be described as flowing in themachine direction through a process from upstream in the process todownstream in the process.

The term “cross direction” (CD) is used herein to refer to a directionthat is generally perpendicular to the machine direction.

The term “pant” (also referred to as “training pant”, “pre-closeddiaper”, “diaper pant”, “pant diaper”, and “pull-on diaper”) refersherein to disposable absorbent articles having a continuous perimeterwaist opening and continuous perimeter leg openings designed for infantor adult wearers. A pant can be configured with a continuous or closedwaist opening and at least one continuous, closed, leg opening prior tothe article being applied to the wearer. A pant can be preformed byvarious techniques including, but not limited to, joining togetherportions of the article using any refastenable and/or permanent closuremember (e.g., seams, heat bonds, pressure welds, adhesives, cohesivebonds, mechanical fasteners, etc.). A pant can be preformed anywherealong the circumference of the article in the waist region (e.g., sidefastened or seamed, front waist fastened or seamed, rear waist fastenedor seamed.

“Pre-fastened” refers herein to pant diapers manufactured and providedto consumers in a configuration wherein the front waist region and theback waist region are fastened or connected to each other as packaged,prior to being applied to the wearer. As such pant diapers may have acontinuous perimeter waist opening and continuous perimeter leg openingsdesigned for infant or adult wearers. As discussed in more detail below,a diaper pant can be preformed by various techniques including, but notlimited to, joining together portions of the diaper using refastenableand/or permanent closure members (e.g., seams, heat bonds, pressurewelds, adhesives, cohesive bonds, mechanical fasteners, etc.). Inaddition, pant diapers can be preformed anywhere along the circumferenceof the waist region (e.g., side fastened or connected, front waistfastened or connected, rear waist fastened or connected).

The present disclosure relates to methods and apparatuses for assemblingabsorbent articles, and more particularly, diapers, each including achassis connected with front and back elastic belts. The chassis mayinclude a topsheet, a backsheet, and an absorbent core disposed betweenthe topsheet and the backsheet. The chassis may also have a first endregion and an opposing second end region separated from each other by acentral region. As discussed in more detail below, opposing end regionsof the chassis are connected with regions of the elastic belts where theelasticity of the elastic belts has been removed or deactivated. Anelastic laminate may be formed by continuously bonding elastic strandsbetween a first continuous substrate layer and a second continuoussubstrate layer such that a first adhesive (referred to herein as the“substrate adhesive”) is continuously applied at a relatively low basisweight to the first and/or second continuous substrate layers. A secondadhesive (referred to herein as the “elastic adhesive”) is alsointermittently applied to the elastic strands. As such, the elasticlaminate includes first regions (referred to herein as “heavy-bond”regions) and second regions (referred to herein as “light-bond” regions)intermittently spaced along the machine direction, wherein the elasticstrands are bonded to both the first substrate layer and the secondsubstrate layer in the heavy-bond regions with both the substrateadhesive and the elastic adhesive. And the elastic strands are bonded tothe first substrate layer and/or the second substrate layer with thesubstrate adhesive in the light-bond regions. The elastic laminate isthen cut along the machine direction to form a first continuous elasticlaminate and a second continuous elastic laminate, each of the firstcontinuous elastic laminate and the second continuous elastic laminateincluding heavy-bond regions and light-bond regions. The firstcontinuous elastic laminate and the second elastic laminate are thenseparated from each other in the cross direction. The elastic strandsare then intermittently deactivated by cutting the strands into one ormore discrete pieces in the light-bond regions of the first continuouselastic laminate and the second elastic laminate.

The discrete pieces of the elastic strands retract and remain in thelight-bond regions. Although the discrete pieces of elastic strands arebonded to the first and second substrates by the substrate adhesive inthe light bond regions, the substrate adhesive is not strong enough tohold the severed elastic ends of the discrete pieces elastic strands inposition on the first and second substrates in the light bond regions.As such, the discrete pieces of elastic strands retract to anunstretched state in the light-bond regions. The adhesive in thelight-bond regions may, however, be strong enough to help control therate at which the discrete pieces retract. Thus, the severed elasticpieces may be configured to retract in the light-bond regions at acontrolled rate dictated in part by the basis weight, adhesiveapplication type, and/or type of substrate adhesive applied in thelight-bond regions. A relatively slow rate of retraction or snap back ofsevered the elastic pieces may result in improved consistency and/orpredictability of the location of the elastic pieces within thecompleted elastic laminate. As such, the first continuous elasticlaminate and the second continuous elastic laminate each have elasticregions corresponding with the first regions, and deactivated regionscorresponding with the second regions where the elastics have been cutinto pieces. A plurality of chassis may then be bonded between first andsecond elastic laminates, wherein first and second end regions of eachchassis is bonded with light-bond regions of first and second continuouselastic laminates.

It is to be appreciated that the elastic laminate can be formed invarious ways. For example, in some embodiments, the first continuoussubstrate layer may be formed from a first continuous substrate, and thesecond continuous substrate layer may be formed from a second continuoussubstrate. In other embodiments, the first continuous substrate layerand/or the second continuous substrate layer may be formed by folding aportion of a single continuous substrate onto another portion of thesingle continuous substrate.

Having the substrate adhesives in the light-bond regions may help enablethe elastic to be cut more uniformly as the adhesive holds the elasticin position long enough for a plurality of cuts to be performed. Inaddition, the adhesive may allow the elastic to retract while at thesame time providing enough adhesion to prevent the elastic from becomingdislodged from the assembled absorbent article, which may lead to poorquality impressions with consumers.

The processes and apparatuses discussed herein may be used to assembleelastic laminates in various types of substrate configurations, some ofwhich may be used in the manufacture of different types of absorbentarticles. To help provide additional context to the subsequentdiscussion of the process embodiments, the following provides a generaldescription of absorbent articles in the form of diapers that includeelastic laminates that may be assembled in accordance with the methodsand apparatuses disclosed herein. Although the methods and apparatusesherein are discussed below in the context of manufacturing absorbentarticles, it is to be appreciated that the assembly methods andapparatuses herein may be configured to manufacture various types ofsubstrates having intermittently spaced elastic and inelastic regions.

FIGS. 1 and 2A show an example of a diaper pant 100 that may beassembled and folded in accordance with the apparatuses and methodsdisclosed herein. In particular, FIG. 1 shows a perspective view of adiaper pant 100 in a pre-fastened configuration, and FIG. 2A shows aplan view of the diaper pant 100 with the portion of the diaper thatfaces away from a wearer oriented towards the viewer. The diaper pant100 shown in FIGS. 1 and 2A includes a chassis 102 and a ring-likeelastic belt 104. As discussed below in more detail, a first elasticbelt 106 and a second elastic belt 108 are connected together to formthe ring-like elastic belt 104.

With continued reference to FIG. 2A, the chassis 102 includes a firstwaist region 116, a second waist region 118, and a crotch region 119disposed intermediate the first and second waist regions. The firstwaist region 116 may be configured as a front waist region, and thesecond waist region 118 may be configured as back waist region. In someembodiments, the length of each of the front waist region, back waistregion, and crotch region may be ⅓ of the length of the absorbentarticle 100. The diaper 100 may also include a laterally extending frontwaist edge 120 in the front waist region 116 and a longitudinallyopposing and laterally extending back waist edge 122 in the back waistregion 118. To provide a frame of reference for the present discussion,the diaper 100 and chassis 102 of FIG. 2A is shown with a longitudinalaxis 124 and a lateral axis 126. In some embodiments, the longitudinalaxis 124 may extend through the front waist edge 120 and through theback waist edge 122. And the lateral axis 126 may extend through a firstlongitudinal or right side edge 128 and through a midpoint of a secondlongitudinal or left side edge 130 of the chassis 102.

As shown in FIGS. 1 and 2A, the diaper pant 100 may include an inner,body facing surface 132, and an outer, garment facing surface 134. Thechassis 102 may include a backsheet 136 and a topsheet 138. The chassis102 may also include an absorbent assembly 140 including an absorbentcore 142 that may be disposed between a portion of the topsheet 138 andthe backsheet 136. As discussed in more detail below, the diaper 100 mayalso include other features, such as leg elastics and/or leg cuffs toenhance the fit around the legs of the wearer.

As shown in FIG. 2A, the periphery of the chassis 102 may be defined bythe first longitudinal side edge 128, a second longitudinal side edge130; a first laterally extending end edge 144 disposed in the firstwaist region 116; and a second laterally extending end edge 146 disposedin the second waist region 118. Both side edges 128 and 130 extendlongitudinally between the first end edge 144 and the second end edge146. As shown in FIG. 2A, the laterally extending end edges 144 and 146are located longitudinally inward from the laterally extending frontwaist edge 120 in the front waist region 116 and the laterally extendingback waist edge 122 in the back waist region 118. When the diaper pant100 is worn on the lower torso of a wearer, the front waist edge 120 andthe back waist edge 122 of the diaper pant 100 may encircle a portion ofthe waist of the wearer. At the same time, the chassis side edges 128and 130 may encircle at least a portion of the legs of the wearer. Andthe crotch region 119 may be generally positioned between the legs ofthe wearer with the absorbent core 142 extending from the front waistregion 116 through the crotch region 119 to the back waist region 118.

It is to also be appreciated that a portion or the whole of the diaper100 may also be made laterally extensible. The additional extensibilitymay help allow the diaper 100 to conform to the body of a wearer duringmovement by the wearer. The additional extensibility may also help, forexample, to allow the user of the diaper 100 including a chassis 102having a particular size before extension to extend the front waistregion 116, the back waist region 118, or both waist regions of thediaper 100 and/or chassis 102 to provide additional body coverage forwearers of differing size, i.e., to tailor the diaper to an individualwearer. Such extension of the waist region or regions may give theabsorbent article a generally hourglass shape, so long as the crotchregion is extended to a relatively lesser degree than the waist regionor regions, and may impart a tailored appearance to the article when itis worn.

As previously mentioned, the diaper pant 100 may include a backsheet136. The backsheet 136 may also define the outer surface 134 of thechassis 102. The backsheet 136 may be impervious to fluids (e.g.,menses, urine, and/or runny feces) and may be manufactured from a thinplastic film, although other flexible liquid impervious materials mayalso be used. The backsheet 136 may prevent the exudates absorbed andcontained in the absorbent core from wetting articles which contact thediaper 100, such as bedsheets, pajamas and undergarments. The backsheet136 may also comprise a woven or nonwoven material, polymeric films suchas thermoplastic films of polyethylene or polypropylene, and/or amulti-layer or composite materials comprising a film and a nonwovenmaterial (e.g., having an inner film layer and an outer nonwoven layer).The backsheet may also comprise an elastomeric film. An examplebacksheet 136 may be a polyethylene film having a thickness of fromabout 0.012 mm (0.5 mils) to about 0.051 mm (2.0 mils). Exemplarypolyethylene films are manufactured by Clopay Corporation of Cincinnati,Ohio, under the designation BR-120 and BR-121 and by Tredegar FilmProducts of Terre Haute, Ind., under the designation XP-39385. Thebacksheet 136 may also be embossed and/or matte-finished to provide amore clothlike appearance. Further, the backsheet 136 may permit vaporsto escape from the absorbent core (i.e., the backsheet is breathable)while still preventing exudates from passing through the backsheet 136.The size of the backsheet 136 may be dictated by the size of theabsorbent core 142 and/or particular configuration or size of the diaper100.

Also described above, the diaper pant 100 may include a topsheet 138.The topsheet 138 may also define all or part of the inner surface 132 ofthe chassis 102. The topsheet 138 may be compliant, soft feeling, andnon-irritating to the wearer's skin. It may be elastically stretchablein one or two directions. Further, the topsheet 138 may be liquidpervious, permitting liquids (e.g., menses, urine, and/or runny feces)to penetrate through its thickness. A topsheet 138 may be manufacturedfrom a wide range of materials such as woven and nonwoven materials;apertured or hydroformed thermoplastic films; apertured nonwovens,porous foams; reticulated foams; reticulated thermoplastic films; andthermoplastic scrims. Woven and nonwoven materials may comprise naturalfibers such as wood or cotton fibers; synthetic fibers such aspolyester, polypropylene, or polyethylene fibers; or combinationsthereof. If the topsheet 138 includes fibers, the fibers may bespunbond, carded, wet-laid, meltblown, hydroentangled, or otherwiseprocessed as is known in the art.

Topsheets 138 may be selected from high loft nonwoven topsheets,apertured film topsheets and apertured nonwoven topsheets. Aperturedfilm topsheets may be pervious to bodily exudates, yet substantiallynon-absorbent, and have a reduced tendency to allow fluids to pass backthrough and rewet the wearer's skin. Exemplary apertured films mayinclude those described in U.S. Pat. Nos. 5,628,097; 5,916,661;6,545,197; and 6,107,539.

As mentioned above, the diaper pant 100 may also include an absorbentassembly 140 that is joined to the chassis 102. As shown in FIG. 2A, theabsorbent assembly 140 may have a laterally extending front edge 148 inthe front waist region 116 and may have a longitudinally opposing andlaterally extending back edge 150 in the back waist region 118. Theabsorbent assembly may have a longitudinally extending right side edge152 and may have a laterally opposing and longitudinally extending leftside edge 154, both absorbent assembly side edges 152 and 154 may extendlongitudinally between the front edge 148 and the back edge 150. Theabsorbent assembly 140 may additionally include one or more absorbentcores 142 or absorbent core layers. The absorbent core 142 may be atleast partially disposed between the topsheet 138 and the backsheet 136and may be formed in various sizes and shapes that are compatible withthe diaper. Exemplary absorbent structures for use as the absorbent coreof the present disclosure are described in U.S. Pat. Nos. 4,610,678;4,673,402; 4,888,231; and 4,834,735.

Some absorbent core embodiments may comprise fluid storage cores thatcontain reduced amounts of cellulosic airfelt material. For instance,such cores may comprise less than about 40%, 30%, 20%, 10%, 5%, or even1% of cellulosic airfelt material. Such a core may comprises primarilyabsorbent gelling material in amounts of at least about 60%, 70%, 80%,85%, 90%, 95%, or even about 100%, where the remainder of the corecomprises a microfiber glue (if applicable). Such cores, microfiberglues, and absorbent gelling materials are described in U.S. Pat. Nos.5,599,335; 5,562,646; 5,669,894; and 6,790,798 as well as U.S. PatentPublication Nos. 2004/0158212 and 2004/0097895.

As previously mentioned, the diaper 100 may also include elasticized legcuffs 156. It is to be appreciated that the leg cuffs 156 can be and aresometimes also referred to as leg bands, side flaps, barrier cuffs,elastic cuffs or gasketing cuffs. The elasticized leg cuffs 156 may beconfigured in various ways to help reduce the leakage of body exudatesin the leg regions. Example leg cuffs 156 may include those described inU.S. Pat. Nos. 3,860,003; 4,909,803; 4,695,278; 4,795,454; and4,704,115; and U.S. Patent Publication No. 2009/0312730A1.

As mentioned above, diaper pants may be manufactured with a ring-likeelastic belt 104 and provided to consumers in a configuration whereinthe front waist region 116 and the back waist region 118 are connectedto each other as packaged, prior to being applied to the wearer. Assuch, diaper pants may have a continuous perimeter waist opening 110 andcontinuous perimeter leg openings 112 such as shown in FIG. 1.

As previously mentioned, the ring-like elastic belt 104 is defined by afirst elastic belt 106 connected with a second elastic belt 108. Asshown in FIG. 2A, the first elastic belt 106 defines first and secondopposing end regions 106 a, 106 b and a central region 106 c, and thesecond elastic 108 belt defines first and second opposing end regions108 a, 108 b and a central region 108 c.

The central region 106 c of the first elastic belt is connected with thefirst waist region 116 of the chassis 102, and the central region 108 cof the second elastic belt 108 is connected with the second waist region118 of the chassis 102. As shown in FIG. 1, the first end region 106 aof the first elastic belt 106 is connected with the first end region 108a of the second elastic belt 108 at first side seam 178, and the secondend region 106 b of the first elastic belt 106 is connected with thesecond end region 108 b of the second elastic belt 108 at second sideseam 180 to define the ring-like elastic belt 104 as well as the waistopening 110 and leg openings 112.

As shown in FIGS. 2A, 3A, and 3B, the first elastic belt 106 alsodefines an outer lateral edge 107 a and an inner lateral edge 107 b, andthe second elastic belt 108 defines an outer lateral edge 109 a and aninner lateral edge 109 b. The outer longitudinally opposed edges 107 a,109 a may also define the front waist edge 120 and the laterallyextending back waist edge 122. The first elastic belt and the secondelastic belt may also each include an outer, garment facing layer 162and an inner, wearer facing layer 164. It is to be appreciated that thefirst elastic belt 106 and the second elastic belt 108 may comprise thesame materials and/or may have the same structure. In some embodiments,the first elastic belt 106 and the second elastic belt may comprisedifferent materials and/or may have different structures. It should alsobe appreciated that the first elastic belt 106 and the second elasticbelt 108 may be constructed from various materials. For example, thefirst and second belts may be manufactured from materials such asplastic films; apertured plastic films; woven or nonwoven webs ofnatural materials (e.g., wood or cotton fibers), synthetic fibers (e.g.,polyolefins, polyamides, polyester, polyethylene, or polypropylenefibers) or a combination of natural and/or synthetic fibers; or coatedwoven or nonwoven webs. In some embodiments, the first and secondelastic belts include a nonwoven web of synthetic fibers, and mayinclude a stretchable nonwoven. In other embodiments, the first andsecond elastic belts include an inner hydrophobic, non-stretchablenonwoven material and an outer hydrophobic, non-stretchable nonwovenmaterial.

The first and second elastic belts 106, 108 may also each include beltelastic material interposed between the outer layer 162 and the innerlayer 164. The belt elastic material may include one or more elasticelements such as strands, ribbons, or panels extending along the lengthsof the elastic belts. As shown in FIGS. 2A, 3A, and 3B, the belt elasticmaterial may include a plurality of elastic strands 168 which may bereferred to herein as outer, waist elastics 170 and inner, waistelastics 172.

As shown in FIG. 2A, the outer, waist elastics 170 extend continuouslylaterally between the first and second opposing end regions 106 a, 106 band across the central region 106 c of the first elastic belt 106 andbetween the first and second opposing end regions 108 a, 108 b andacross the central region 108 c of the second elastic belt 108. In someembodiments, some elastic strands 168 may be configured withdiscontinuities in areas. For example, as shown in FIG. 2A, the inner,waist elastics 172 extend intermittently along the first and secondelastic belts 106, 108. More particularly, the inner, waist elastics 172extend along the first and second opposing end regions 106 a, 106 b andpartially across the central region 106 c of the first elastic belt 106.The inner, waist elastics 172 also extend along the first and secondopposing end regions 108 a, 108 b and partially across the centralregion 108 c of the second elastic belt 108. As such, the inner, waistelastics 172 do not extend continuously across the entirety of thecentral regions 106 c, 108 c of the first and second elastic belts 106,108. As discussed in more detail below and as shown in FIGS. 2A and 2B,the inner, waist elastics 172 may be cut into one or more discretelengths or pieces 168 a in the central regions 106 c, 108 c of the firstand second elastic belts 106, 108. More particularly, the elasticstrands 172 are cut into pieces 168 a and are deactivated in the centralregions 106 c, 108 c. As such, elasticity imparted by the elasticstrands 172 is removed from the first and second elastic belts 106, 108in the regions where the elastic strands 172 are cut into pieces 168 a.

Thus, some elastic strands 168 may not extend continuously throughregions of the first and second elastic belts 106, 108 where the firstand second elastic belts 106, 108 overlap the absorbent assembly 140. Insome embodiments, some elastic strands 168 may partially extend intoregions of the first and second elastic belts 106, 108 where the firstand second elastic belts 106, 108 overlap the absorbent assembly 140. Insome embodiments, some elastic strands 168 may not extend into anyregion of the first and second elastic belts 106, 108 where the firstand second elastic belts 106, 108 overlap the absorbent assembly 140. Itis to be appreciated that the first and/or second elastic belts 106, 108may be configured with various configurations of discontinuities in theouter, waist elastics 170 and/or the inner, waist elastic elastics 172.

In some embodiments, the elastic strands 168 may be disposed at aconstant interval in the longitudinal direction. In other embodiments,the elastic strands 168 may be disposed at different intervals in thelongitudinal direction. It is also to be appreciated that the elasticstrands may have a variable decitex and/or opacity. Further, in someembodiments, elastic strands may extend along straight lines and/orcurved lines. As discussed in more detail below, the belt elasticstrands 168, in a stretched condition, may be interposed and joinedbetween the uncontracted outer layer and the uncontracted inner layer.When the belt elastic material is relaxed, the belt elastic materialreturns to an unstretched condition and contracts the outer layer andthe inner layer. The belt elastic material may provide a desiredvariation of contraction force in the area of the ring-like elasticbelt.

It is to be appreciated that the chassis 102 and elastic belts 106, 108may be configured in different ways other than as depicted in FIG. 2A.For example, FIG. 2B shows a plan view of a diaper pant 100 having thesame components as described above with reference to FIG. 2A, except thefirst laterally extending end edge 144 of the chassis 102 is alignedalong and coincides with the outer lateral edge 107 a of the firstelastic belt 106, and the second laterally extending end edge 146 isaligned along and coincides with the outer lateral edge 109 a of thesecond belt 108.

As previously mentioned, the apparatuses and methods according to thepresent disclosure may be utilized to assemble various components ofdiapers 100. For example, FIG. 4 shows a schematic view of a convertingapparatus 300 adapted to manufacture pant diapers 100. The method ofoperation of the converting apparatus 300 may described with referenceto the various components of pant diapers 100 described above and shownin FIGS. 1 and 2A. Although the following methods are provided in thecontext of the diaper 100 shown in FIGS. 1 and 2A, it is to beappreciated that various embodiments of diapers and associatedcomponents, such as for example leg cuffs and waist bands, can bemanufactured according the methods disclosed herein, such as forexample, the absorbent articles disclosed in U.S. Pat. Nos. 7,569,039and 5,745,922; U.S. Patent Publication Nos. 2005/0107764A1,2012/0061016A1, and 2012/0061015A1; and the U.S. patent applicationentitled “Methods and Apparatuses for Making Leg Cuffs for AbsorbentArticles,” filed Mar. 30, 2012, which are all hereby incorporated byreference herein.

As described in more detail below, the converting apparatus 300 shown inFIG. 4 operates to advance discrete chassis 102 along a machinedirection MD initially with the longitudinal axis parallel to themachine direction and subsequently cutting the chassis web and turningthe separate chassis such that the lateral axis of each chassis 102 isparallel with the machine direction, and wherein the chassis 102 arespaced apart from each other along the machine direction. Opposing waistregions 116, 118 of the spaced apart chassis 102 are then connected withcontinuous lengths of advancing first and second elastic belt substrates406, 408. The chassis 102 are then folded along the lateral axis tobring the first and second elastic belt substrates 406, 408 into afacing relationship, and the first and second elastic belt substratesare connected together along intermittently spaced seams 336. And theelastic belt substrates 406, 408 are cut along the seams 336 to creatediscrete diapers 100, such as shown in FIG. 1.

As shown in FIGS. 4 and 5A, a first continuous substrate layer in theform of a continuous length of outer layer belt material 162; a secondcontinuous substrate layer in the form of a continuous length of innerlayer belt material 164; and elastics 168 are combined to form acontinuous elastic laminate in the form of a belt material 402. Moreparticularly, continuous lengths of outer layer belt material 162, innerlayer belt material 164, outer elastic strands 170 and inner elasticstrands 172 are advanced in a machine direction MD and combined at niprolls 502 to form a continuous length of belt material 402. Beforeentering the nip rolls 502, the outer elastic strands 170 and innerelastic strands 172 are stretched in the machine direction MD. Inaddition, adhesive 504 may be applied to the elastic strands 170, 172 aswell as either or both of the continuous lengths of outer layer beltmaterial 162 and inner layer belt material 164 before entering nip rolls502. More particularly, a first adhesive 504A (referred to herein as“substrate adhesive”) may be continuously applied to the either or bothof the continuous lengths of outer layer belt material 162 and innerlayer belt material 164. Further, a second adhesive 504B (referred toherein as “elastic adhesive”) may be applied intermittently along thelengths of the inner elastic strands 172 and/or intermittently along thelength of either or both of the continuous lengths of outer layer beltmaterial 162 and inner layer belt material 164 before entering nip rolls502. For the purposes of clarity, the substrate adhesive 504A isrepresented by shaded or darkened regions in FIGS. 5B3 and 5C4; and theelastic adhesive 504B is represented by cross-hatch regions surroundingportions of elastics 168, 172 in FIGS. 5B3 and 5C4.

As such, the substrate adhesive 504A may be applied to one or more ofthe outer layer belt material 162, the inner layer belt material 164,the outer elastic strands 170, and the inner elastic strandscontinuously along the machine direction MD. In addition, the elasticadhesive 504B is intermittently applied to the inner elastic strands 172and/or either or both of the continuous lengths of outer layer beltmaterial 162 and inner layer belt material 164 along the machinedirection MD. More particularly, as shown in FIG. 5A, the belt material402 may include first regions 403 (referred to herein as “light-bondregions”) intermittently spaced between second regions 405 (referred toherein as “heavy-bond regions”) 405 along the machine direction MD.Thus, the inner elastic strands 172 are bonded to either the outer layerbelt material 162 or inner layer belt material 164 in the light-bondregions 403 with only the substrate adhesive 504A. And the inner elasticstrands 172 are bonded to the outer layer belt material 162 and/or innerlayer belt material 164 in the heavy-bond regions 405 with elasticadhesive 504B and in certain embodiments the substrate adhesive 504A orcombinations thereof. For the purposes of clarity, dashed lines 401 areshown in FIG. 5A and others to represent example boundaries between thelight-bond regions 403 and the heavy-bond regions 405. It is to beappreciated that such boundaries between the light-bond regions 403 andthe heavy-bond regions 405 can also be curved, angled, and/or straight.It is to be appreciated that in some embodiments, the heavy-bond regionsmay continuously extend from one side edge of a substrate layer to alaterally opposing side edge, while the light-bond regions may belaterally discontinuous. It is also to be appreciated that the elasticadhesive 504B and/or the substrate adhesive 504A can be intermittentlyapplied and alternating along the machine direction such that theelastics are continuously bonded, but with alternating adhesiveapplications. It is also to be appreciated that in some embodiments, theelastic adhesive 504B and/or the substrate adhesive 504A can beintermittently applied such that the application of the adhesivesoverlap with each other.

Although FIG. 4 shows an embodiment wherein the belt material 402 isformed by combining continuous lengths of outer layer belt material 162and inner layer belt material 164 with elastic strands 168, it is to beappreciated the belt material 402 can be formed in various other ways.As previously mentioned, the first continuous substrate layer and thesecond continuous substrate layer may be formed by a folding portion ofa single continuous substrate onto another portion of the singlecontinuous substrate. For example, FIG. 4A shows an embodiment whereinthe belt material 402 is formed by combining continuous lengths ofelastic strands 168 with a single continuous length of belt material 160having a first surface 161 a and an opposing second surface 161 b. Moreparticularly, the continuous lengths of outer elastic strands 170 andinner elastic strands 172 are advanced in a machine direction MD andcombined with the first surface 161 a of the belt material 160 at drum528. Before being combined at drum 528, the outer elastic strands 170and inner elastic strands 172 are stretched in the machine direction MD.From the drum 528, the combined elastics 170, 172 and the belt material160 advance to a folding apparatus 530 adapted to fold a portion of thefirst surface 161 a of the belt material 160 onto another portion of thefirst surface 161 a such that the elastics 170, 172 are intermittentlybonded between the folded portions of the belt material 160. In thearrangement shown in FIGS. 4A and 4A1, elastic adhesive 504B may beapplied intermittently to the elastic strands 170, 172 and/or thecontinuous length of belt material 160 before entering the folder 530.For example, FIG. 4A1 shows an arrangement wherein the belt material 160includes opposing longitudinal edges 160 a, 160 b and laterally opposededge regions 166 a, 166 b separated by a central region 166 c. And theelastics are combined with the central region 166 c of the first surface161 a of the belt material 160. The folder 530 folds the opposing edgeregions 166 a, 166 b onto the central region 166 c. As such, theelastics are sandwiched between the first surface 161 a of the opposingedge regions 166 a, 166 b and the first surface 161 a of the centralregion 166 c. Thus, an elastic laminate can be formed wherein the firstsubstrate layer may comprise the central region 166 c, and wherein thesecond substrate layer may comprise the folded edge regions 166 a, 166b. From the folder 530, the combined elastics 168 and the belt material160 may enter nip rolls 502 to form the belt material 402.

It is to be appreciated that the belt material may be folded in variousways at the 530. For example, in some embodiments, the elastics 168 maybe combined with the belt material 160 in such a way that the folder 530need only fold the belt material 160 once along the center region 166 c.For example, the folder 530 may fold the first surface 161 a of the beltmaterial 160 onto itself such that the first longitudinal edge 161 a isaligned with the second longitudinal edge 161 b.

In yet another example embodiment shown in FIG. 4B, the belt material402 is formed by first combining continuous lengths of outer elasticstrands 170 with the opposing edge regions 166 a, 166 b of singlecontinuous length of belt material 160 at drum 528. Before beingcombined at drum 528, the outer elastic strands 170 are stretched in themachine direction MD. From the drum 528, the combined elastics 170 andthe belt material 160 advance to a folding apparatus 530 adapted to foldthe opposing edge regions 166 a, 166 b onto themselves. As such, theouter elastics 170 are sandwiched between first surfaces 161 a of theopposing edge regions 166 a, 166 b, such as shown in FIG. 4B1. From thefolder 530, the outer elastics 170 and belt material 160 are combinedwith the inner elastics 172 and the inner belt material 164 at nip rolls502 to form the belt material 402 as shown in FIG. 4B2. Thus, an elasticlaminate can be formed wherein the first substrate layer may comprisethe central region 166 c, and wherein the second substrate layer maycomprise the folded edge regions 166 a, 166 b. In the arrangement shownin FIGS. 4B-4B2, elastic adhesive 504B may be applied to the elasticstrands 170 and/or the continuous length of belt material 160 beforeentering the folder 530.

Referring back to FIG. 4, from the nip rolls 502 the continuous lengthof belt material 402 advances in the machine direction MD to a cutter506 that cuts the belt material 402 into two continuous belt substrates,referred to as a first belt substrate 406 and a second belt substrate408. The cutter 506 may be configured in various ways. For example, insome embodiments the cutter 506 may be a slitter or a die cutter thatseparates the belt material into two continuous belt substrates witheither a straight line cut and/or a curved line cut. The cutter 506 mayalso be configured as a perforator that perforates the belt materialwith a line of weakness and wherein the belt material is separated alongthe line of weakness in a later step. From the cutter 506, the first andsecond belt substrates 406, 408 advance through a diverter 508 thatseparates the first and second belt substrates from each other in thecross direction CD, such as shown in FIG. 5B. The elastic strands 170,172, and thus, the continuous length of first and second belt substrates406, 408 are maintained in a stretched condition while advancing alongthe machine direction MD.

It is to be appreciated that the diverter 508 may be configured invarious ways. For example, in some embodiments, the diverter 508 mayinclude turn bars angled at 45 degrees or some other angle with respectto the machine direction. In some embodiments, the diverter may includecambered rollers. Other embodiments may include diverters in the form ofa pivot table, such as, for example, the FIFE-500 Web Guiding System, byMaxcess-FIFE Corporation. The diverter may also include instrumentationand web edge control features that allow for precise active control ofthe substrate positions.

With continued reference to FIGS. 4, 5B, 5B1, 5B2, and 5B3, the firstand second belt substrates 406, 408 advance from the diverter 508 to acutting unit 510. The cutting unit 510 then intermittently deactivatesthe elastics 168 in the first and second belt substrates 406, 408. Moreparticularly, the cutting unit 510 may sever, cut, and/or break theinner elastics 168, 172 in the light-bond regions 403 into one or morediscrete pieces 168 a of elastic material. As such, the first and secondbelt substrates 406, 408 each have elastic regions 405 correspondingwith the heavy-bond regions 405, and deactivated regions 403corresponding with the light-bond regions 403 where the elastics 172have been cut into discrete pieces 168 a.

As shown in FIGS. 5C-5C4, the discrete pieces 168 a of elastic materialwill remain in the light-bond regions 403. And the severed ends 404 ofthe discrete pieces of the inner elastics 172 will retract toward eachother until the induced strain is substantially relieved as the beltsubstrates advance in the machine direction. In addition, the severedends 404 of the inner elastics 172 will retract or snap back in acontrolled fashion to the heavy-bond regions 405 of the first and secondbelt substrates 406, 408 as the belt substrates advance in the machinedirection, and depending on the rate of retraction, may continue toretract once the assembled absorbent article has been packaged. Aspreviously mentioned, although the inner elastics 172 are bonded to theouter layer belt material 162 or the inner layer belt material 164 bythe substrate adhesive 504A in the light bond regions, the substrateadhesive 504A is not strong enough to hold the severed elastic ends 404in a strained or stretched conditioned within the light bond regions403. But the substrate adhesive 504A may be strong enough to hold theelastic pieces 168 a in desired positions in the light-bond regions 403.At the same time, the substrate adhesive 504A allows the elastic pieces168 a to retract such that the cut elastics are deactivated in thelight-bond regions.

It is to be appreciated that the substrate adhesive 504A and the elasticadhesive 504B may be applied in various ways and in various amountsdepending on the particular application. For example, in some instances,the substrate adhesive 504A may be applied with a porous slot coatmethod. In some configurations, the substrate adhesive 504A may beapplied in amounts ranging from 0.5 gsm to 10 gsm. It is to beappreciated that the adhesion strength (high versus low) can be variedin various ways. For example, in some embodiments, adhesion strength canbe varied by the process techniques in which adhesive may be applied fora given type of adhesive. Some example application process techniquesmay include slot coating, meltblown, and spiral pattern applications. Insome embodiments, adhesion strength can be varied by the basis weight inwhich adhesive is applied for a given type of adhesive. In someembodiments, adhesion strength can be varied by the type of adhesivethat is applied, such as for example, a hot-melt adhesive sold under theproduct code PHO-3000 available from H.B. Fuller. In some embodiments,adhesion strength can be varied by the compression forces, such as withnonwoven substrates, wherein compression forces may affect how deepadhesives may be pressed into nonwoven fibers.

In some embodiments such as shown in FIGS. 5C2 and 5C3, the cutting unit510 may be configured to sever only the elastics 168, 172 in thelight-bond regions 403 of the first and/or second belt substrates 406,408 without cutting through either the outer layer belt material 162 orthe inner layer belt material 164. In other configurations, the cuttingunit 510 may be configured to cut the elastics 168, 172 in thelight-bond regions 403 of the first and second belt substrates 406, 408while also cutting through one or both the outer layer belt material 162and the inner layer belt material 164. For example, FIGS. 5C2A and 5C3Ashow a configuration where the cutting unit 510 cuts slits 413 throughthe inner layer belt material 164 while cutting the elastics 168, 172 inthe light-bond regions 403 of the first and second belt substrates 406,408, without cutting through the outer layer belt material 162. Inanother example, FIGS. 5C2B and 5C3B show a configuration where thecutting unit 510 cuts slits 413 through both the inner layer beltmaterial 164 and the outer layer material 162 while cutting the elastics168, 172 in the light-bond regions 403 of the first and second beltsubstrates 406, 408. Also, in some embodiments, such as shown in FIGS.5C2B and 5C3B, the slits 413 in the outer layer material 162 may beoffset or staggered relative to the slits 413 in the inner layermaterial 164 along the machine direction, as illustrated by the relativepositions of center lines 413 a of the slits 413.

As previously discussed, the inner elastic strands 172 are bonded to theouter layer belt material 162 and/or inner layer belt material 164 inthe light-bond regions 403 with only the substrate adhesive 504A.However, it is to be appreciated that the light-bond regions 403 andheavy-bond regions 405 may be configured with various adhesiveapplications. For example, FIG. 5B3 shows a detailed view of a beltsubstrate 408 with the outer layer belt material 164 cut-away toillustrate an embodiment of adhesive application in the heavy-bondregions 405 and the light-bond regions 403. More particularly, FIG. 5B3shows an example adhesive application configuration wherein substrateadhesive 504A has been applied to the belt materials 162, 164 and/orelastics 168, 170, 172 in the heavy-bond regions 405 and the light bondregions 403. In addition, elastic adhesive 504B has been applied eitheror both belt materials 162, 164, and/or the inner elastics 168, 172, inthe heavy-bond regions 405, but not the light bond regions 403. As such,elastic adhesive 504B may be intermittently applied along the machinedirection MD in the heavy-bond regions 405, and substrate adhesive 504Amay be continuously applied along the machine direction in thelight-bond regions 403 and the heavy-bond regions 405.

With continued reference to FIG. 5B3, elastic adhesive 504B may beapplied to the elastics 168, 172 extending the machine direction MD inthe heavy-bond regions 405. As such, the elastic adhesive 504B bonds theinner layer belt material 162, the outer layer belt material 164, andthe elastics 168, 172 together in the heavy-bond regions 405. Inaddition, substrate adhesive 504A may be applied to one or more of theelastics 168, 172, the inner belt material 162, or the outer beltmaterial 164 extending in the machine direction MD in the light-bondregions 403 and heavy-bond regions 405. As such, the substrate adhesive504A bonds the inner layer belt material 162 and the outer layer beltmaterial 164 together in the light-bond regions 403. As previouslymentioned, the substrate adhesive 504A is not strong enough to hold thesevered ends 404 of elastics 168, 172 in a prestrained or stretchedstate to either the inner layer belt material 162 or the outer layerbelt material 164 in the light-bond regions 403 after having been cut.FIG. 5C3 shows a detailed view of the belt substrate 408 from FIG. 5B3with the outer layer belt material 164 cut-away to illustrate theelastics 168, 172 after having been cut in the light-bond regions 403wherein the severed ends 404 of the elastics 168, 172 have retracted orsnapped back to the heavy-bond regions 405.

It is to be appreciated that various configurations of cutting units 510can be used with the apparatuses and methods herein. Such cutting unitconfigurations may include features of the cutting knives/unitsdisclosed, for example, in U.S. Pat. Nos. 5,393,360; 7,708,849;7,861,756; 7,777,094; U.S. patent application Ser. No. 13/434,912, filedon Mar. 30, 2012; and U.S. Patent Application No. 61/617,713, filed onMar. 30, 2012, which are all incorporated by reference herein. As such,the cutting units may be configured with die knife, flexible blade,and/or compression roll features, and may also include additionalfeatures to control knife-anvil gaps and/or force.

FIGS. 6 and 7 show an example embodiment of a cutting unit 510 includinga cutting roll 600 and an anvil roll 602. The cutting roll 600 isadapted to rotate around an axis of rotation 604 and defines an outercircumferential surface 606. And the anvil roll 602 is adapted to rotatearound an axis of rotation 608 and defines an outer circumferentialsurface 610. The cutting roll 600 is adjacent to the anvil roll 602 andcreate a nip 603 defined by a minimum distance, D, between the outercircumferential surface 606 of the cutting roll 602 and the outercircumferential surface 610 of the anvil roll 602. As shown in FIGS. 6and 7, the cutting roll 600 may also include one or more blades 612.Each blade 612 may have a proximal end portion 614 extending in a crossdirection (CD) a length, L, along the outer circumferential surface 606of the cutting roll 600. The blades 612 may define a dimension, H1,extending from the proximal end portion 614 to a distal edge 616. Inaddition, from the proximal end portion 614, the blades may extendradially outward from the outer circumferential surface 606 of thecutting roll 600 to the distal edge 616 by a distance, H. It is to beappreciated that the blades 612 may extend radially outward from theouter circumferential surface 606 to define an angle of 90 degrees orless, such as about 45 degrees, between the blade 612 and a tangentialplane intersecting the proximal end portion 614 on the outercircumferential surface 606. As such, in some embodiments, H1 may beequal to H, and in some embodiments, H1 may be greater than H. As shownin FIGS. 6 and 7, the blades 612 may define a rectangular shape having afirst surface 618 and an opposing second surface 620 separated by athickness, t. The blades 612 may have a small thickness, t, relative tothe distance, H1, such that blades 612 are flexible or bendable.

As shown in FIGS. 6-8C, the cutting unit 510 may be arranged such thatthe first and second belt substrates 406, 408 advance in a machinedirection MD to partially wrap around the outer circumferential surface610 of the anvil roll 602. As the anvil roll 602 and the cutting roll600 rotate, portions of the first surfaces 618 and the distal edges 616of the blades 612 are moved into contact with the first and second beltsubstrates 406, 408, such as shown in FIG. 8A. As shown in FIGS. 8A-8C,the distance, H, of each blade 612 is greater than the distance, D,between the cutting roll 600 and the anvil roll 602. Thus, withreference to FIG. 8B, as the blades 612 rotate though the nip 603between the cutting roll 600 and the anvil roll 602, the blades 612 flexor bend inward along the second surface 620. As such, portions of thefirst surfaces 618 and/or the distal edges 616 of the blades 612 exertpressure on the first and second belt substrates 406, 408 to cut theelastics 168, 172 in the light-bond regions 403. Referring now to FIG.8C, as the cutting roll 600 continues to rotate, the blades 612 moveaway from the nip 603 and straighten back out along the distance, H1,thus returning to the original blade shapes before entering the nip 603.

It is to be appreciated that the belt substrate materials may bearranged in various ways on the cutting unit 510. For example, as shownin FIGS. 6-8C, the front belt substrate material 406 and the back beltsubstrate material 408 may advance in the machine direction MD topartially wrap around the rotating anvil roll 602 such that the outerlayer belt material 162 of the front belt substrate material 406 and theback belt substrate material 408 are in contact with the outercircumferential surface 610 of the anvil roll 602. As such, the blades612 of the rotating cutting roll 600 contact the inner layer beltmaterial 164 of the front belt substrate material 406 and the back beltsubstrate material 408 while advancing through the nip 603. It is to beappreciated that the front and back belt substrates 406, 408 may bearranged such that either the inner layer of belt material 162 or theouter layer of belt material 164 is in contact with the outercircumferential surface 610 of the anvil roll 602. For example, in someembodiments, the front belt substrate material 406 and the back beltsubstrate material 408 may be arranged to partially wrap around therotating anvil roll 602 such that the inner layer of belt material 162of the front belt substrate material 406 and the back belt substratematerial 408 are in contact with the outer circumferential surface 610of the anvil roll 602. As discussed above, the cutting unit 510 shown inFIGS. 6-8C may be configured to sever only the elastics 168, 172 in thelight-bond regions 403 of the first and/or second belt substrates 406,408 without cutting through either the outer layer belt material 162 orthe inner layer belt material 164. In other configurations, the cuttingunit 510 may be configured to cut the elastics 168, 172 in thelight-bond regions 403 of the first and second belt substrates 406, 408while also cutting through one or both the outer layer belt material 162and the inner layer belt material 164.

It is to be appreciated that the cutting unit 510 may be configured withvarious quantities of blades having various shapes and orientations. Forexample, the cutting unit 510 shown in FIGS. 6-8C includes four blades612 a, 612 b, 612 c, 612 d. The first and second blades 612 a, 612 b maybe located 180 degrees apart from the third and fourth blades 612 c, 612d on the outer circumferential surface 606 of the cutting roll 600. Itis to be appreciated that the cutting roll may also be configured withvarious numbers of blades arranged circumferentially along the outercircumferential surface 606 of the cutting roll 600. The proximal endportions 614 of the first blade 612 a and the second blade 612 b mayalso be aligned with each other and with the axis of rotation 604 so asto extend in a straight line in the cross direction (CD) perpendicularto the machine direction (MD). Similarly, proximal end portions 614 ofthe third blade 612 c and the fourth blade 612 d may be aligned witheach other and with the axis of rotation 604 so as to extend in astraight line in the cross direction (CD) perpendicular to the machinedirection (MD). In addition, the first blade 612 a and the second blade612 b, as well as the third and fourth blades 612 c, 612 d, may definedifferent lengths, L, and may separated from each other by variousdistances in the cross direction CD. For example, the lengths, L, of theblades 612 are configured such so as to engage portions of the first andsecond belt substrates 406, 408 so as to cut the elastics 168, 172without cutting elastics 168, 170. In addition, the blades 612 may beconfigured to cut the elastics 168, 172 simultaneously in the CDdirection along in a substantially straight line. It is also to beappreciated that the cutting roll 600 may be configured with more thanor less than two blades 612 aligned along the CD direction of outercircumferential surface 606 of the cutting roll 600. For example, insome embodiments, instead of having the first blade 612 a and the secondblade 612 b, the cutting roll 600 may be configured with a single blade612 extending along the CD direction for a length, L, on the outercircumferential surface 606. It is also to be appreciated that thecutting roll 600 may be configured to cut the elastics more than once ina zone or region. For example, the cutting roll 600 may be configured tocut the elastics 168, 172 more than once in a light-bond region 403.

Referring back to FIG. 4, from the cutting unit 510, the first andsecond belt substrates 406, 408 advance in the machine direction MD andare combined with discrete chassis 102. As shown in FIGS. 4 and 5D, acontinuous length of chassis assemblies 302 are advanced in a machinedirection MD to a carrier apparatus 512 and cut into discrete chassis102 with knife roll 514. As shown in FIG. 5D, the continuous length ofchassis assemblies 302 may include absorbent assemblies 140 sandwichedbetween topsheet material 138 and backsheet material 136, leg elastics,barrier leg cuffs and the like. A portion of the chassis assembly iscut-away to show a portion of the topsheet material 138 and an absorbentassembly 140.

After the continuous web of absorbent chassis 102 are cut by the kniferoll 514, the carrier apparatus 512 rotates and advances the discretechassis 102 in the machine direction MD in the orientation shown in FIG.5E1, wherein the longitudinal axis 124 of the chassis 102 is rotatedfrom generally parallel with the machine direction MD to a position thatis generally perpendicular to the machine direction. While the chassis102 shown in FIG. 5E1 is shown with the second laterally extending endedge 146 as a leading edge and the first laterally extending end edge144 as the trailing edge, it is to be appreciated that in otherembodiments, the chassis 102 may be advanced in other orientations. Forexample, the chassis may be oriented such that the second laterallyextending end edge 146 is a trailing edge and the first laterallyextending end edge 144 is a leading edge. The carrier apparatus 308 alsorotates while at the same time changing the orientation of the advancingchassis 102. The carrier apparatus 308 may also change the speed atwhich the chassis 102 advances in the machine direction MD. It is to beappreciated that various forms of carrier apparatuses may be used withthe methods herein, such as for example, the carrier apparatusesdisclosed in U.S. Pat. No. 7,587,966. FIG. 5E2 shows an orientation ofthe chassis 102 on the carrier apparatus 308 while advancing in themachine direction that is different from that depicted in FIG. 5E1. Moreparticularly, FIG. 5E2 shows the chassis 102 with the lateral axis 126of the chassis 102 generally parallel with the machine direction MD, andwherein the first longitudinal side edge 128 is the leading edge and thesecond longitudinal side edge 130 is the trailing edge.

As discussed below with reference to FIGS. 4, 5F, 5G, and 5H, thechassis 102 are transferred from the carrier apparatus 512 and combinedwith advancing, continuous lengths of belt substrates 406, 408, whichare subsequently cut to form first and second elastic belts 106, 108 ondiapers 100.

With reference to FIGS. 4 and 5F, the chassis 102 are transferred fromthe carrier apparatus 512 to a nip 516 between the carrier apparatus 512and a roll 518 where the chassis 102 are combined with continuouslengths of advancing front belt substrate material 406 and back beltsubstrate material 408. The front belt substrate material 406 and theback belt substrate material 408 each define a wearer facing surface 312and an opposing garment facing surface 314. The wearer facing surface312 of the first belt substrate 406 may be combined with the garmentfacing surface 134 of the chassis 102 along the first waist region 116,and the wearer facing surface 312 of the second belt substrate 408 maybe combined with the garment facing surface 134 of the chassis 102 alongthe second waist region 118. As shown in FIG. 4, adhesive 520 may beintermittently applied to the wearer facing surface 312 of the first andsecond belt substrates 406, 408 before combining with the discretechassis 102 at the nip 516 between roll 518 and the carrier apparatus512. In some embodiments, the chassis 102 may be joined to the first andsecond belts in various different ways, such as for example, thermalbonds, pressure bonds, ultrasonic bonds, adhesives and combinationsthereof.

In some embodiments, such as shown in FIGS. 4, 5C, 5C1, 5C2, and 5F,adhesive 520 may be intermittently applied to portions of the bodyfacing surface 312 at the light-bond regions 403 of the first beltsubstrate 406 and/or the second belt substrate 408. And adhesive may notbe applied to portions of the body facing surface 312 at the heavy-bondregions 405 of the first belt substrate 406 and/or the second beltsubstrate 408. As such, the garment facing surface 134 of the chassis102 may be combined in an overlapping relationship with the light-bondregions 403 of the first belt substrate 406 and/or the second beltsubstrate 408. As such, in some embodiments, the light-bond regions 403of the first and second belt substrates 406, 408 may correspond withand/or define the central regions 106 c, 108 c of the first and secondelastic belts 106, 108 discussed above with reference to FIGS. 1-2B. Inaddition, the heavy-bond regions 405 may correspond with and/or definethe opposing end regions 106 a, 106 b, 108 a, 108 b of the of the firstand second elastic belts 106, 108 discussed above with reference toFIGS. 1-2B.

As mentioned above, the converting process can be configured in variousways such that the severed elastic ends retract within the light-bondregions at a controlled rate dictated in part by the basis weight and/ortype of substrate adhesive applied in the light-bond regions. As such,in some embodiments, the chassis 102 can be placed on the light-bondregions 403 before the severed elastics 168, 172 have fully retracted.In some embodiments, the chassis 102 can be placed on the light-bondregions 403 after the severed elastics 168, 172 have fully retracted. Itshould also be appreciated that the heavy-bond regions 405 andlight-bond regions 403 may have various sizes relative to the chassis102. For example, in some embodiments, portions of the chassis 102 mayoverlap or may be positioned on top of the severed ends 404 and/orportions of the severed elastics 168, 172. In some embodiments, thesevered ends 404 of the elastics 168, 172 may be aligned with or may beoutside of the longitudinal edges 128, 130 of the chassis 102. In someembodiments, the severed elastics may not be fully retracted untilpositioned within an assembled absorbent article placed within apackage.

With reference to FIGS. 4 and 5F, a continuous length of absorbentarticles 400 are defined by multiple discrete chassis 102 spaced fromeach other along the machine direction MD and connected with each otherby the second belt substrate 408 and the first belt substrate 406. Asshown in FIG. 4, the continuous length of absorbent articles 400advances from the nip 516 to a folding apparatus 522. At the foldingapparatus 522, each chassis 102 is folded in the cross direction CDalong a lateral axis 126 to place the first waist region 116, andspecifically, the inner, body facing surface 132 into a facing, surfaceto surface orientation with the inner, body surface 132 of the secondwaist region 118. The folding of the chassis also positions the wearerfacing surface 312 of the second belt substrate 408 extending betweeneach chassis 102 in a facing relationship with the wearer facing surface312 of the first belt substrate 406 extending between each chassis 102.As shown in FIGS. 4, 5F, and 5G, the folded discrete chassis 102connected with the first and second belt substrates 406, 408 areadvanced from the folding apparatus 522 to a bonder 524. The bonder 524operates to bond a portion of the second belt substrate 408 extendingbetween each chassis 102 with a portion of the first belt substrate 406extending between each chassis 102, thus creating discrete bond regions336. It is to be appreciated that various types of bonder apparatusesand methods can be used to bond the second belt substrate material 408with the first belt substrate material 406, such as for exampledisclosed in U.S. Pat. Nos. 6,248,195; 6,546,987; and 7,383,865, as wellas U.S. Patent Publication No. 2012/0021186A1, which are incorporated byreference herein.

As shown in FIGS. 4 and 5H, a continuous length of absorbent articlesare advanced from the bonder 524 to a knife roll 526 where the discretebond regions 336 are cut along the cross direction to create a firstside seam 178 on an absorbent article 100 and a second side seam 180 ona subsequently advancing absorbent article.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method for assembling disposable diapers, each diaper comprising a chassis having a first end region and an opposing second end region separated from each other by a central region, and having a longitudinal axis and a lateral axis, the chassis comprising: a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet, the method comprising the steps of: advancing a first continuous substrate layer having a first surface and an opposing second surface in a machine direction, and defining a width in a cross direction; advancing a second continuous substrate layer having a first surface and an opposing second surface in a machine direction, and defining a width in a cross direction; applying a first adhesive continuously along the machine direction to the first surface of the first continuous substrate layer; advancing elastic strands in the machine direction in a stretched state; applying a second adhesive intermittently along the machine direction to at least one of the elastic strands, the first surface of the first continuous substrate layer, and the first surface of the second continuous substrate layer; bonding the elastic strands in the stretched state directly to the first surface of the first substrate layer and directly to the first surface of the second substrate layer to form an elastic laminate, the elastic laminate including first regions that include the first adhesive and not the second adhesive, and second regions including both the first adhesive and the second adhesive, the second regions intermittently spaced along the machine direction; cutting the elastic laminate along the machine direction to form a first continuous elastic laminate and a second continuous elastic laminate, each of the first continuous elastic laminate and the second continuous elastic laminate including first regions and second regions; separating the first continuous elastic laminate and the second elastic laminate in the cross direction; severing elastic strands into one or more discrete lengths in the first regions of the first continuous elastic laminate and the second elastic laminate, wherein ends of the severed elastic strands retract from the first regions to the second regions, and wherein severing the elastic strands further comprises cutting the first slits in the first continuous substrate layer in the first regions and cutting second slits in the second continuous substrate layer in the first regions, wherein the first slits are offset from the second slits in the machine direction; and bonding the first end regions of each chassis with first regions of first continuous elastic laminate, and bonding the second end regions of each chassis with first regions of the second continuous elastic laminate.
 2. The method of claim 1, wherein the step of severing the elastic strands further comprises cutting the elastic strands and the first continuous substrate layer in the first regions without cutting the second continuous substrate layer.
 3. The method of claim 1, further comprising the steps of: advancing a third continuous web in the machine direction; cutting the third continuous web into discrete chassis, wherein each chassis advances such that the longitudinal axis is parallel with the machine direction; and turning each chassis such that the lateral axis is parallel with the machine direction.
 4. The method of claim 3 further comprising the steps of: folding each chassis along the lateral axis to position the first continuous elastic laminate into a facing relationship with the second continuous elastic laminate; bonding the first continuous elastic laminate with the second continuous elastic laminate at discrete bond regions; and cutting the first and second continuous elastic laminates to form diaper side seams.
 5. The method of claim 1, wherein the first end region is a front waist region.
 6. The method of claim 1, wherein the second end region is a back waist region. 